Molded surgical mask

ABSTRACT

A molded surgical cup mask of three-ply construction, the first and third plies being of polyester batting acrylic emulsion bonded to form a durable film, the intermediate ply being unbonded microglass and the plies being molded into a unit by heat and pressure.

United States Patent Inventor Thomas Thackston Florhlm Park, NJ. Appl. No. 840,405 Filed July 9, 1969 Patented Nov. 16, 1971 Assignee C. R. Bard, Inc.

Murray Hill, NJ.

MOLDED SURGICAL MASK 5 Claims, 3 Drawing Figs.

11.8. CI 128/l46.2, 161/156 Int. Cl A62b 23/02 Field of Search 128/l46.2, 146, 141,141 A,205, 146.6; 161/156, 152,203, 204

[56] References Cited UNITED STATES PATENTS 3,316,904 5/1967 Wall et al 128/146.6 2,552,124 5/1951 Tallman 161/156X 3,333,585 8/1967 Barghini et a1 128/2 l 2 FOREIGN PATENTS 548,150 10/1957 Canada t. 161/156 Primary Examiner-Richard A. Gaudet Assistant ExaminerG. F Dunne Anomey- W. Saxton Seward ABSTRACT: A molded surgical cup mask of three-ply construction, the first and third plies being of polyester batting acrylic emulsion bonded to form a durable film, the intermediate ply being unbonded microglass and the plies being molded into a unit by heat and pressure.

PATENTEDuuv 1s I97l 3,620,214

I N VENT 0R. THOMAS THACKSTQN Roma/"1mm ATTORNEYS MOLDED SURGICAL MASK While both polyester materials and glass fibers have been used in surgical masks, the particular combination disclosed herein constitutes a sufficiently rigid, shapely, highly efficient mask with excellent breathability, as well as being washable and readily sterilized.

A practical embodiment of the invention is shown in the accompanying drawing, wherein:

FIG. 1 represents a flow diagram, in perspective, of the method of forming the mask;

FIG. 2 represents a perspective view of the completed mask; and

FIG. 3 represents a vertical medial section through the mask.

Referring to the drawings, the components of the mask are shown as including a layer of polyester batting l, a layer of ti]- tering material 2 and a second layer of polyester batting 3, similar to the layer 1. The polyester batting may suitably be bonded by the addition of an acrylic binder such as Rhoplex B-lS" (Rohm and Haas) which has good mechanical, chemical and dimensional stability, water resistance and flexibility. The filter material 2 is preferably unbonded microglass, which may, for example, have a fiber diameter of 0.75 to 1.5 microns, the layer having a thickness of 0.004 to 0.005 inch and net weight, in grams per square foot, of l '6 to 3 i.

The layers 1, 2 and 3 are brought together in a cup-shaped mold and subjected to heat (e.g. 325 F. and pressure sufficient to cause impregnation of the layer 2 by the acrylic emulsion of the layers 1 and 3, with a cycle of 3 to seconds depending on thickness and required rigidity, thus forming a shaped unit 4, as shown in FIG. 2.

A bendable metal nose strip 5 is adhesively attached and an elastic headband 6 is connected at its end to each side of the mask.

It is desirable to mold into the central part of the mask several horizontally disposed undulations or corrugations 7 which not only increase somewhat the efiective area in relation to the outside dimensions but also help the mask to retain its form.

The elastic headband 6 has its ends attached to suitable points 8 at each side of the mask, spaced from the edge thereof, for holding the entire edge of the mask finnly against the wearer's face.

What is claimed is:

l. A surgical mask comprising a body having a cupped shape and being formed of inner and outer layers of polyester batting stabilized by acrylic emulsion and an intermediate filtering layer of inherently unstabilized fine-spun microglass composed substantially of fibers having a diameter of 0.75 to 1.5 microns bonded to said inner and outer layers to constitute a self-supporting dimensionally stable unit.

2. A mask according to claim 1 wherein the material of the intermediate layer is initially unbonded.

3. A mask according to claim 1 provided with horizontally disposed corrugations.

4. A mask according to claim 2 wherein the intermediate layer is impregnated by the acrylic emulsion.

5. A mask according to claim 1 wherein the microglass is in the form of a layer having a thickness of 0.004 inch to 0.005 inch and net weight of 1% to 3% grams per square foot. 

1. A surgical mask comprising a body having a cupped shape and being formed of inner and outer layers of polyester batting stabilized by acrylic emulsion and an intermediate filtering layer of inherently unstabilized fine-spun microglass composed substantially of fibers having a diameter of 0.75 to 1.5 microns bonded to said inner and outer layers to constitute a selfsupporting dimensionally stable unit.
 2. A mask according to claim 1 wherein the material of the intermediate layer is initially unbonded.
 3. A mask according to claim 1 provided with horizontally disposed corrugations.
 4. A mask according to claim 2 wherein the intermediate layer is impregnated by the acrylic emulsion.
 5. A mask according to claim 1 wherein the microglass is in the form of a layer having a thickness of 0.004 inch to 0.005 inch and net weight of 1 1/2 to 3 1/2 grams per square foot. 